Metatarsal joint shape for prosthetic foot and control mechanism and system for same

ABSTRACT

A prosthetic foot can include a plate-like foot member extending along a longitudinal axis between an anterior end generally corresponding to a toe portion of a foot to a posterior end, and a metatarsal hinge comprising an elongate groove extending between medial and lateral edges of the foot member. The elongate groove can intersect the longitudinal axis of the foot member, and can be positioned along the length of the foot member at a location generally corresponding to a metatarsal region of the foot. The metatarsal hinge can also comprise a plurality of elongate apertures that extend completely through the foot member, or a plurality of recessed channels that extend only partially through the foot member, or a combination thereof.

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

Any and all applications for which a foreign or domestic priority claimis identified in the Application Data Sheet as filed with the presentapplication are hereby incorporated by reference under 37 CFR 1.57. Thisapplication is a continuation of U.S. application Ser. No. 13/032,495(Atty Docket No. OSSUR.115A), filed Feb. 22, 2011, which claims priorityunder 35 U.S.C. §119(e) as a nonprovisional of U.S. Provisional App. No.61/307,267 (Atty Docket No. OSSUR.115PR), filed Feb. 23, 2010. Thisapplication is also related to U.S. patent application Ser. No.12/509,055 (Atty Docket No. OSSUR.050CP1C2), filed Jul. 24, 2009, whichis a continuation of U.S. patent application Ser. No. 10/987,940 (AttyDocket No. OSSUR.050CP1), filed Nov. 12, 2004, now issued as U.S. Pat.No. 7,846,213, which is a continuation-in-part of U.S. patentapplication Ser. No. 10/944,436 (Atty Docket No. OSSUR.050A), filed Sep.17, 2004, now issued as U.S. Pat. No. 7,347,877, which claims priorityto Provisional App. No. 60/575,142 (Atty Docket No. OSSUR.050PR), filedMay 28, 2004. The entire contents of each of these references is herebyincorporated by reference and should be considered a part of thisspecification.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present application relates in certain embodiments to prostheticfeet. In particular, the present application in certain embodimentsrelates to prosthetic feet with an articulatable metatarsal joint.

2. Description of the Related Art

Prosthetic feet are known in the art that are designed to replicate thenatural function of human feet. These prosthetic feet may includecomponents designed to mimic the natural function of ankles, heels andtoes.

There is much difficulty in developing a prosthetic foot that mimics thenatural function of human toes. The challenges may be even greater whentrying to replicate a human toe that can account for other physicalmodifications of the prosthetic foot. For example, a user of aprosthetic foot may be able to modify its heel height by providing ankleadjustments. When the heel height is modified without adjusting othersections of the prosthetic foot (e.g., the toe region), this results inan unnatural position of the prosthetic foot that can create discomfortfor the user or provide a less than optimal rollover performance duringambulation.

Despite advancements in prosthetics, there remains an on-going need toprovide a prosthetic foot that properly captures the function of naturalhuman toes by providing metatarsal functionality. The prosthetic footshould be capable of assisting in walking and providing balance,weight-bearing, thrust during gait and proper push-off patterns. Theprosthetic foot should also be able to accommodate different types ofheel-height adjustment.

SUMMARY OF THE CLAIMS

An improved prosthetic foot designed for providing metatarsalfunctionality is described. In one embodiment, the prosthetic footincludes a generally plate-like foot member that extends along alongitudinal axis between an anterior end, which can correspond to a toeportion, and a posterior end, which can correspond to a heel portion.The prosthetic foot can include an elongate groove that can extendacross the width of the foot member between medial and lateral edges ofthe foot member so that the groove intersects the longitudinal axis ofthe foot member. In one embodiment, the elongate groove extendsgenerally transverse to the longitudinal axis of the foot member fromthe lateral edge to the medial edge of the foot member. The position ofthe elongate groove generally corresponds to a metatarsal region of thefoot.

In another embodiment, a prosthetic foot is provided comprising aplate-like foot member extending along a longitudinal axis between ananterior end generally corresponding to a toe portion of a foot to aposterior end. The foot member includes a top surface and a bottomsurface opposite the top surface, wherein the bottom surface isconfigured to contact a support surface during ambulation of theprosthetic foot. The foot member can comprise at least one elongategroove defined on the top surface, wherein the elongated groove extendsbetween medial and lateral edges of the foot member and intersects thelongitudinal axis of the foot member. The elongated groove can bepositioned along the length of the foot member at a location generallycorresponding to a metatarsal region of a foot and can be configured toallow the anterior portion of the foot to controllably articulaterelative to the posterior end of the foot. A filler material can bedisposed in the elongate groove. The filler material can be configuredto vary the rate and/or degree of articulation of the anterior portionof the foot relative to the posterior end of the foot.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an upper cross-sectional view of a human foot.

FIG. 2 illustrates a perspective view of a schematic of a prostheticfoot having a metatarsal hinge according to embodiments of the presentapplication.

FIG. 3A illustrates a cross-sectional view of a metatarsal hingecomprised of an unfilled groove according to embodiments of the presentapplication.

FIG. 3B illustrates a cross-sectional view of the groove in FIG. 3Afilled with a filler material according to embodiments of the presentapplication.

FIG. 4A illustrates a cross-sectional view of a metatarsal hingecomprised of an unfilled groove having raised side supports according toembodiments of the present application.

FIG. 4B illustrates a cross-sectional view of the groove of FIG. 4Afilled with a filler material according to embodiments of the presentapplication.

FIG. 5 illustrates a side view of a schematic of a prosthetic foothaving a metatarsal hinge according to embodiments of the presentapplication.

FIG. 6A illustrates a top view of a prosthetic foot having a metatarsalhinge formed of a plurality of apertures according to embodiments of thepresent application.

FIG. 6B illustrates a cross-sectional view of the prosthetic foot inFIG. 6A.

FIG. 6C illustrates an exploded view of a portion of the prosthetic footin FIG. 6B having apertures filled with a filler material.

FIG. 6D illustrates a cross-sectional view of an alternate embodiment ofa prosthetic foot having a metatarsal hinge formed of a plurality ofrecessed grooves according to embodiments of the present application.

FIG. 6E illustrates a top view of a contour of a foot includingmetatarsal point C.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Improved prosthetic feet are described that are capable of providingmetatarsal functionality and mimicking the natural function of humanfeet. In particular, the prosthetic feet described herein include ametatarsal joint shape and control mechanism and system that can includea metatarsal hinge that provides metatarsal functionality. Theprosthetic feet described herein advantageously assist in achieving thegoals described above, including providing balance, improved push-offpatterns and thrust during gait, even following heel-height adjustment.

FIG. 1 illustrates an upper cross-sectional view of a human foot. Thehuman foot 1 serves as a mechanical structure having bones, joints,muscles, tendons and ligaments. Bones in the human foot includemetatarsal bones 6 and shorter phalanges 8 that form the toes.Metatarsophalangeal joints exist between the metatarsal bones 6 andphalanges 8. These joints assist in providing joint articulation of thephalanges 8 relative to the metatarsal bones 6, such as at the naturalmetatarsal angles 14 identified in FIG. 1, which allows the posterior orheel of the foot to be angled relative to the forefoot or toes of thefoot. Said articulation allows the use of shoes of varying heel heightswhile providing support and balance.

In view of the challenges described above, the present applicationdiscloses an improved prosthetic foot having a metatarsal joint shapeand control mechanism or system that advantageously mimics themetatarsal joints of a natural human foot, thereby providing metatarsalfunctionality and easily accommodating heel-height adjustment of theprosthetic foot. The metatarsal joint shape and control system caninclude one or more elongate gaps, channels, apertures, or groovesformed in the prosthetic foot (e.g., formed on a surface of a prostheticfoot plate). The position of the grooves generally corresponds to ametatarsal region of the foot. In some embodiments, the metatarsalregion of the foot comprises approximately ¼ to ⅓ or more of the footlength from an anterior edge of the foot. In other embodiments, to findthe metatarsal region, the length of the foot can be multiplied by0.618, and this distance can be travelled from a posterior edge. Thegrooves can be open or filled with a resilient material, and can be usedto provide the prosthetic foot with metatarsal functionality, allowingthe prosthetic foot to articulate via the metatarsal joint.

FIG. 2 illustrates a schematic of a prosthetic foot having a metatarsalhinge according to some embodiments of the present application. Theprosthetic foot 100 can comprise a curved plate-like foot member 102having a top surface 115 and bottom surface 118, as well as an upperportion 109 and a toe region 112. In one embodiment, at least a portionof the foot member 102 is generally planar. In one embodiment, atransverse cross-section of the foot member 102 can be generallyrectangular. The foot member 102 can further include attachment holes117 and a split 134 along its longitudinal axis that separates theplate-like member into two sections: a medial blade having medial edge138 and a lateral blade having lateral edge 139. In other embodiments,the foot member 102 can have more than one longitudinal split or slot134 defining two or more blades. In still another embodiment, the footmember 102 can be a single foot plate without a longitudinal split orslot. The foot member 102 can have a metatarsal hinge generally at thelocation of the metatarsal region in a natural human foot. In oneembodiment, the metatarsal hinge can include a channel or groove 148that intersects the longitudinal axis of the prosthetic foot. In oneembodiment, the metatarsal hinge intersects the split or slot 134 of thefoot member 102.

The foot member 102 of the prosthetic foot 100 can be a curvedplate-like member having a posterior edge formed by the upper portion109 and an anterior edge formed by the toe region 112. In shape, theplate-like foot member 102 includes a vertical upper portion 109 thatslopes and curves downwardly before flattening out near the toe portion112. At the toe portion 112, the foot member 102 slopes and curvesupwardly and provides a slight raise from the ground at the anteriorend. While the foot member 102 is shown on its own in FIG. 2, in someembodiments, the foot member can be operably connected to a heel member,as shown in FIGS. 5 and 6B.

In some embodiments, portions of the prosthetic foot (such as the footmember or heel member) can be constructed of a strong, resilientmaterial that is capable of flexing in multiple directions, particularlyduring heel-strike through toe-off. The material can comprise multiplelayers, or laminate. In some embodiments, the multiple layers orlaminates when assembled form a monolithic foot member 102 of theprosthetic foot 100. Examples of possible materials for the prostheticfoot 100 include carbon, any polymer material, and any composite ofpolymer and fiber. The polymer can be thermoset or thermoplastic. In acomposite, the fiber reinforcement can be any type of fiber or filament,such as carbon, glass or aramid. The fibers can be long andunidirectional, or they can be chopped and randomly oriented. Otherfilaments, such as Kevlar and nylon, can also be used to ensurelightweight and structurally dynamic characteristics.

The upper portion 109 of the foot member 102 can be attached to adaptersand/or pylons for prosthetic limbs. While not shown in FIG. 2,attachment holes can be provided on the upper portion 109 to assist inattaching these additional components. Other than or in addition to theattachment holes that can be provided on the upper portion 109 of theprosthesis, attachment holes 117 can also be provided on other sectionsof the prosthetic foot, such as below the upper portion 109 closer tothe anterior end of the foot. These attachment holes 117 can be used toaffix the plate-like member to other members (e.g., a lower, plate-likeheel member) by using mechanical screws, fasteners or bolts. An exampleof a prosthetic foot having an upper member attached to a lower memberby use of attachment holes is shown in FIG. 5 and discussed furtherbelow. However, other suitable mechanisms can be used to attach theplate-like member to other members (e.g., adapter, heel plate, etc.).For example various adhesives may also be used to affix the plate-likemember to other members.

The split 134 is located along the longitudinal axis of the foot member102 and can help provide desirable roll-over properties. The split 134is of a length that is between approximately ⅕ and ⅘ of the longitudinallength of the foot member 102, can begin at a distance that is betweenapproximately ⅕ and ⅘ of the distance away from the posterior end of thefoot member, and can extend to the distal edge of the foot member (i.e.,to the edge of the toe region of the foot member). The split 134separates portions of the foot member 102 into a medial blade havingmedial edge 138 and a lateral blade having lateral edge 139. While inFIG. 2, the medial blade and the lateral blade have equivalent widths,in other embodiments, the split 134 can form blades of unequal width. Inaddition, while the split 134 is entirely straight along a longitudinalaxis of the foot member 102, in other embodiments, the split 134 has astraight portion followed by a curved portion that curves either in alateral or medial direction toward the distal end of the foot member. Inyet another embodiment, the split 134 can have a curved shape withoutany straight portions.

As shown in FIG. 2, the foot member 102 of the prosthetic foot 100includes a metatarsal hinge comprising a gap, channel or groove 148 thatcan extend across the width of the foot member between medial andlateral edges of the foot member. In the illustrated embodiment, thegroove 148 is formed as a recessed portion in the top surface 115 of thefoot member 102. However, while the groove 148 is illustrated on a topsurface 115 of the foot member 102, in other embodiments, the groove canbe located on a bottom surface 118 of the foot member 102, or in betweena top surface and bottom surface. In some embodiments, the groove 148extends completely across the prosthetic foot, from one part of themedial edge to one part of the lateral edge, while in other embodimentsthe groove 148 extends across only a portion of the prosthetic foot. Thegroove 148 can intersect the longitudinal axis of the foot member 102.In some embodiments, the groove 148 can be generally transverse to thelongitudinal axis of the foot member 102, and even perpendicular to thelongitudinal axis, as shown in FIG. 2. In other embodiments, the groove148 intersects the longitudinal axis of the foot member 102 at an angleother than 90 degrees, such as between 20 and 80 degrees. The prostheticfoot 100 comprising the groove 148 can be formed by special layupsequencing, where the groove 148 is defined by one or more layers, butfewer than all layers, that make up the foot member 102 of theprosthetic foot 100, or by cutting the groove through material layers ofthe foot member 102 of the prosthetic foot 100 after said layers havebeen laid.

Such techniques can be used to position the elongate groove 148generally near or around the metatarsal region of the foot. In someembodiments, the metatarsal region or “toe section” of the foot canextend a length (either planar or curvilinear depending on the shape ofthe region) between about 0.5 cm and 20 cm, as measured from an anteriorend (e.g., anterior edge) of the foot to the groove 148. One skilled inthe art will appreciate that the length of the toe section is notlimited to these lengths, and that the length can be determined inproportion to the length of the prosthetic foot. Providing a suitablelength of the metatarsal region advantageously provides an effective toelength that helps to accommodate various stride lengths. With the groove148 positioned generally near or around the metatarsal region, theprosthetic foot 100 is capable of flexing and comfortably accommodatingheel height adjustments.

In one embodiment, the groove 148 can include sidewalls 216 that help toform the particular shape of the groove within the foot member 102. Insome embodiments, the groove 148 includes sidewalls 216 that arestraight, curved, or tapered. In some embodiments, the sidewalls 216include “teeth” formed by elevations and depressions that can furtherhelp to enclose deposited filler material. From a cross-sectional view,the groove can be curved (e.g., generally circular), u-shaped, v-shaped,square-shaped, or any other suitable shape. For example, as illustratedin FIGS. 3A-4B, which show cross-sectional views of groove 148, thegroove 148 can be shaped like a valley, having its narrowest point inits center or bottom most point.

The groove 148 can further take on various dimensions. In someembodiments, the depth D of the groove can be between 1/20 and 9/10 ofthe cross-sectional thickness of a section of the foot member oralternatively, the average height of the foot member itself. In otherembodiments, the average width W of the groove (e.g., the distance fromone sidewall of the groove to another sidewall) can be between 5 mm and20 mm, more preferably between 5 mm and 10 mm. In one embodiment, thedepth of the groove 148 can vary along the length L of the groove(illustrated in FIG. 2). For example, the depth D of the groove 148 canincrease toward the medial edge of the foot member. The medial side ofthe foot member would thus be more flexible than the lateral side of thefoot member, and thus, the groove helps to direct rollover of the footmember in the medial direction. Alternatively, the depth of the groove148 can increase toward the lateral edge of the foot member. The lateralside of the foot member would thus be more flexible than the lateralside of the foot member, and thus, the groove helps to direct rolloverof the foot member in the lateral direction. In addition, in someembodiments, the width W of the groove 148 can vary along the length L(e.g., it can increase in either a medial or lateral direction) of thegroove to assist in directing rollover toward a medial or lateral edgeof the foot member. One skilled in the art will appreciate, however,that the dimensions of the groove are not so limited, and that otherdimensions are also possible, as the measurements of the groove can bedetermined in proportion to the type and/or thickness of a correspondingprosthetic foot. Advantageously, the groove 148 can help accommodateheel-height adjustment, such as would occur if the user wore a high-heelshoe 18 as shown in FIG. 2.

While the metatarsal hinge in FIG. 2 is illustrated as a single straightgroove 148 that intersects the longitudinal axis of the foot member 102in a generally transverse manner, in other embodiments, the metatarsalhinge can be formed of more than one groove. The one or more grooves canintersect the longitudinal axis of the foot member 102 of the prostheticfoot 100 at various angles, including along the natural metatarsalangles 14 of the human foot, as shown in FIG. 1. In some embodiments,the one or more grooves can include one or more portions that aretransverse to the longitudinal axis, as well as one or more otherportions that are slanted or placed at an angle from the portions thatare transverse from the longitudinal axis. In some embodiments, relativeto a segment of the foot member that is perpendicular to thelongitudinal axis, the one or more grooves can have one or more portionsthat are at a slanted angle between about 0 and 85 degrees, morepreferably between 0 and 45 degrees, to provide for metatarsalfunctionality. In one embodiment, the one or more grooves can have oneor more portions that are at a slanted angle between about 0 and 20degrees relative to a line perpendicular to the longitudinal axis (e.g.,slanted at an angle of 90 to 110 degrees relative to the longitudinalaxis).

While the groove 148 shown in FIG. 2 is formed on a top surface 115 ofthe curved plate-like foot member 102 of the prosthetic foot 100 (e.g.,where the top surface 115 is a surface opposite the bottom surface 118that can operatively contact a support surface, such as a floor, duringambulation), in some embodiments, the groove 148 can be formed on abottom-surface 118 near the toe section. In other embodiments, anopening can be formed mid-way between a top-surface 115 andbottom-surface 118 near the toe section, such that the opening is onlyexposed on the side of the prosthetic foot. In still another embodiment,one or more grooves 148 can be formed on both the top and bottomsurfaces of the foot member 102 of the prosthetic foot 100. Regardlessof whether the opening or groove 148 is formed on a top surface, abottom surface, or mid-way between a top surface and bottom surface ofthe curved plate-like foot member 102 of the prosthetic foot 100, thegroove 148 can serve as an articulatable metatarsal joint that canremain open or be filled with a filler material, as discussed below.Furthermore, regardless of where the groove 148 is formed, the curvedplate-like foot member 102 of the prosthetic foot 100 can still comprisea single piece whose body extends from a proximal edge to a distal edge.

While in some embodiments, the groove 148 can be left open (as shown inFIG. 2), in other embodiments, the groove 148 can be filled with afiller material 154. In some embodiments, the filler material cancomprise a liquid, gel or solid (e.g., a solid insert insertable in thegroove 148). In some embodiments, the filler material can comprise oneor more polymers alone or in combination, such as polyurethane orsilicone, as well as various other thermoplastic and thermosettingmaterials. Preferably, the filler material comprises a viscoelasticmaterial comprising one or more types of synthetic polymers orelastomers, such as a gummy-material. Suitable elastomers can include,but are not limited to, materials under the trade names of Silly Putty,Sorbothane, Implus or Noene. In some embodiments, one or more grooves148 can be filled with a combination of various materials as describedabove. In some embodiments, the filler material can be introduced intothe groove 148 in liquid form prior to hardening upon placement in thegroove 148. The various materials that can be inserted into the groove148 can be resilient, and in some embodiments, can have a stiffness thatdiffers from the other material of the prosthetic foot 100.

By adding the filler material 154 to the groove 148, a number ofadvantages can be achieved, including providing an adjustable stiffnessor spring constant at or near the metatarsal region of the foot member,as well as enhanced resistance to deflection. For example, in oneembodiment in which a high-heel adjustment is made, it may be desirableto provide no filler material, or a filler material 154 that providesgreat flexibility. If a filler material 154 is provided, upon removal ofthe high-heel adjustment, the material is resilient such that is canreturn to an original, unstressed state. In addition, in embodiments inwhich the foot member is formed of multiple layers, the filler materialcan help prevent layers from loosening and separating, thereby helpingto keep the layers in place.

Forming a groove 148 near the toe section of the foot member 102 of theprosthetic foot 100 (with or without filler material) provides theprosthetic foot with an articulatable metatarsal hinge that is capableof flexing and adjusting at the natural metatarsal angles of the foot.By providing the metatarsal hinge, the prosthetic foot 100 is capable ofcomfortably articulating and flexing in various positions before, duringand after heel-height adjustment. In some embodiments, adding an elasticfiller material in the groove 148 advantageously helps to furthercontrol the extent of articulation by the metatarsal hinge. The elasticfiller material, which can vary in stiffness depending on the materialused, can help to provide a controlled return of the prosthetic foot toits normal position following heel height adjustment.

In some embodiments, a housing member (not shown) is provided that canenclose the deposited filler material. The housing member can includesidewalls that enhance the function of the filler material. For example,in some embodiments, the housing provides a constant volume for thefiller material. In addition, the sidewalls of the housing can provideconstraints for the movement of the filler material (e.g., floatingliquid material) that can be contained in the housing. In someembodiments, the housing member can be formed with the groove 148 (e.g.,as a lining member) that receives the filler material. In anotherembodiment, the housing can have generally the same cross-sectionalshape as the groove 148. An optional cap or lining layer can be providedover the filler material to enclose the filler material once it isdeposited in the prosthetic foot. In other embodiments, the housingmember can accompany and surround the filler material (e.g., as amembrane) such that both can be inserted into and packed into the groove148 simultaneously. Alternatively, or in addition to the housing member,the metatarsal hinge can include raised side supports 218, as shown inFIGS. 4A and 4B.

In some embodiments, the filler material 154 can be removable andreplaceable after being deposited in the groove 148. For example, insome embodiments, the filler material 154 can be kept in one or moremembranes as a package or insert that can be readily inserted andsubsequently removed from the groove 148. By providing packages orinserts of filler material that are removable and/or replaceable, thisadvantageously allows the prosthetic foot to be used with an evengreater array of heel-height adjustments.

FIG. 3A illustrates a cross-sectional view of a metatarsal hingecomprised of an unfilled groove according to embodiments of the presentapplication. The unfilled groove 148 has curved sidewalls 216 that forma valley. As shown in FIG. 3A, the curved sidewalls 216 of the groove148 are positioned below the top surface 115 of the foot member. Theunfilled groove 148 can be formed near a toe section of a prostheticfoot and can help provide articulatable metatarsal function.

FIG. 3B illustrates a cross-sectional view of the groove of FIG. 3Afilled with a filler material. The filler material 154 can be selectedfrom any of the filler material described above, and preferablycomprises a viscoelastic liquid. As shown in FIG. 3B, the fillermaterial can occupy the entire volume of the groove 148. However, inother embodiments, the filler material need only occupy a portion of thevolume of the groove 148 (e.g., a quarter of the volume or half of thevolume). In some embodiments, the filler material 154 advantageouslyhelps to provide greater control over the flexing and articulation ofthe metatarsal joint mechanism.

FIG. 4A illustrates a schematic of a metatarsal hinge in the form of agroove 148 having raised side supports 218 according to some embodimentsof the present application. In contrast to the sidewalls 216 that arepositioned below the top surface 115 of the plate-like foot member, theraised side supports 218 extend from and above the top surface 115 ofthe plate-like foot member. While the raised side supports 218 can betriangularly-shaped wings, as shown in FIG. 4A, in other embodiments,the raised side supports 218 can take on other shapes and forms (e.g.,they can be square or rectangular). In some embodiments, the raised sidesupports 218 comprise raised flanges that extend from the top surface ofthe grooves. In some embodiments, the raised side supports 218 extend ata height of between about 1 mm and 50 mm above the upper surface of theplate-like member. The raised side supports 218 advantageously providean increased volume for receiving filler material in the groove 148,thereby allowing for even greater metatarsal functionality. In someembodiments, the raised side supports 218 extend along an entire lengthL of the groove (shown in FIG. 2), while in other embodiments, theraised side supports 218 extend only along a portion of the entirelength L of the groove. For example, the raised side supports 218 can bepositioned along a portion of the groove that is less than the width ofthe foot. In some embodiments, the raised side supports 218 can beformed continuously along at least a portion of the length of thegroove, while in other embodiments, the raised side supports 218 can bestaggered along at least a portion of the length of the groove.

In some embodiments, the raised side supports 218 are formed with theplate-like foot member 102 of the prosthetic foot 100 (e.g., by a metalinjection molding). In other embodiments, the raised side supports 218are formed separately from the foot member 102 of the prosthetic foot100 and subsequently attached (e.g., by an adhesive or by a screw). Oneskilled in the art will appreciate that the housing and raised sidesupports 218 are optional, and it is possible to provide a fillermaterial that is flush against the sidewalls of the groove 148.

Preferably the raised side supports are composed of a resilient andcompressible material capable of some flexing which does not interferewith the user when wearing various shoes (e.g., high heels). In someembodiments, the raised side supports are composed of various polymers,such as EVA or polyurethane. Various elastomers such as those describedwith respect to the filler material can also be used. In someembodiments, the raised side supports are composed of low compressibleor non-compressible materials, including polymers of epoxides,polyamides, polycarbonates, polyimides, polyetherimides, and siliconepolymers.

FIG. 4B illustrates a cross-sectional view of the groove of FIG. 4Afilled with a filler material according to embodiments of the presentapplication. With the addition of the raised side supports 218, fillermaterial 154 can optionally be deposited in the groove 148 to a heightabove the top surface of the groove 148 (e.g., above the top surface 115of the foot member), as shown in FIG. 4B. In some embodiments, theadditional filler material 154 deposited in the groove 148 above the topsurfaces of the grooves 148 provides additional resilience and controlover the flexibility and articulation of the metatarsal hinge.

The metatarsal hinge described above can be used with a variety of otherprosthetic feet in addition to those described above. FIG. 5 shows onesuch example of an alternative prosthetic foot 200 for which themetatarsal hinge can be used with. The prosthetic foot 200 includes anupper element 212 having a forefoot portion 217 and a posterior portion219, a lower element 214, an adapter element 208 and groove 148 formedin a top surface 118 of the upper element 212. In some embodiments, theupper element 212 comprises a foot plate, while the lower element 214comprises a heel plate that is operably attached to the foot plate.

The upper element 212 includes the forefoot portion 217, the posteriorportion 219, and a curved portion therebetween. In another embodiment,the upper element 212 can be generally planar. In some embodiments, across-sectional area of the upper element 212 can be generallyrectangular. The forefoot portion 217 comprises a metatarsal region ortoe section. In one embodiment, at least a portion of the forefootportion 217 can be generally horizontal and extend from an anterior end202, or forward edge, of the prosthetic foot 200 toward a posterior end204, or rearward edge, of prosthetic foot 200. The forefoot portion 217can curve upward via a curvilinear portion and transition to theposterior portion 219 of the upper element 212. A top surface 115 of theposterior portion 219 of the upper element 212 can be operably connectedto an adapter element 208 (e.g., via fasteners).

An unfilled groove 148 is located within or proximate to a forefootportion 217 of the upper element 212 of the prosthetic foot 200. Theunfilled groove 148 serves as an articulatable metatarsal hinge. Whilenot shown, in another embodiment, a filler material can be provided inthe groove 148 of the upper element 212 of the prosthetic foot 200, asdiscussed above.

As shown in FIG. 5, a bottom surface 118 of the upper element 212 can bedisposed above the lower element 214. In one embodiment, at least aportion of the lower element 214 can be disposed adjacent and in contactwith at least a portion of the bottom surface 118 of the upper element212. In one embodiment, the upper element 212 can be operably coupled(e.g., via fasteners 220) to the lower element 214. The lower element214 can serve as a heel member. In another embodiment, instead of theupper element 212 and lower element 214 being two separate piecesattached to one another, the upper element 212 and the lower element 214can be one piece. The prosthetic foot 200 can interact with theambulation, or walking, surface, via contact with lower element 214which serves as a heel member. In still another embodiment (not shown),the upper and lower elements can be generally parallel along at least aportion of their lengths and separated at least in part by acompressible material. In one embodiment, the lower element can bedisposed below and spaced apart from the upper element along its entirelength.

FIG. 6A illustrates a top view of a prosthetic foot having a metatarsalhinge formed of a plurality of apertures according to embodiments of thepresent application. FIG. 6B illustrates a cross-sectional view of theprosthetic foot in FIG. 6A with the plurality of apertures unfilled witha filler material, while FIG. 6C illustrates an exploded view of aportion of the prosthetic foot in FIG. 6B having apertures filled with afiller material. FIG. 6D illustrates a cross-sectional view of analternate embodiment of a prosthetic foot having a metatarsal hingeformed of a plurality of recessed grooves according to embodiments ofthe present application.

FIG. 6A illustrates a top view of a prosthetic foot having a metatarsalhinge formed of a plurality of elongate apertures that extend completelythrough the prosthetic foot. The prosthetic foot 300 can comprise acurved plate-like foot member 102 having a top surface 115, a bottomsurface 118, a medial edge 138, a lateral edge 139 and a toe region 112.As shown in FIG. 6B, the curved plate-like foot member 102 can beoperably attached to a heel member 105, such that at least a portion ofthe bottom surface 118 of the foot member 102 is in contact with a topsurface of the heel member 105. A plurality of apertures 348 can extendthrough the top surface 115 of the foot member 102. In the illustratedembodiment in FIG. 6A, the plurality of apertures 348 extend completelythrough the foot member 102 of the prosthetic foot 300, from a topsurface 115 to a bottom surface 118 (identified in FIG. 6B). However, inother embodiments, the apertures or grooves can extend only partlythrough the foot member 102 of the prosthetic foot 300, such that theplurality of apertures resemble recessed channels or grooves, as shownin FIG. 6D. As shown in FIG. 6A, the apertures 348 can have sidesrepresented by a width W′ and a length L′. At least some of sides of theapertures 348 can be in parallel with one another. Providing apertures348 advantageously help the prosthetic foot to be more flexible, andallows the foot to mimic more accurately the biomechanical function ofthe anatomical foot.

In some embodiments, the plurality of elongate apertures 348 can beformed generally along a line that intersects a longitudinal axis of thefoot. In some embodiments, the plurality of elongate apertures 348 canbe formed generally along a line that is perpendicular to a longitudinalaxis of the foot, while in other embodiments, the elongate apertures 348can be formed generally along a line that while not perpendicular, isaskew, to a longitudinal axis of the foot. For example, as shown in FIG.6E, the plurality of elongate apertures 348 can be formed along the line312 from point D across metatarsal point C to point E, which is at anangle of approximately 110° relative to the longitudinal axis defined bypoints A and B.

As shown in FIG. 6A, the plurality of apertures 348 can be formed acrossa width of the prosthetic foot. In some embodiments, the plurality ofapertures 348 can each be of similar dimensions (e.g., same width W′ andlength L′), while in other embodiments, some apertures may be of adifferent dimension than others (e.g., have a different width W′ and/orlength L′). For example, as shown in FIG. 6A, apertures 348 a and 348 chave a smaller length L′ than apertures 348 b and 348 d. In addition,while the apertures 348 are illustrated as rectangular in shape,apertures of other shapes, such as circular, oval, square or triangular,can also be formed. For example, the prosthetic foot can comprise ametatarsal hinge formed of a series of circular apertures formed throughthe prosthetic foot to provide metatarsal functionality. In addition, acombination of apertures of various shapes and sizes can also beprovided. In some embodiments, the apertures can be formed by performinga watercut on the carbon layers (e.g., using a water jet cutter), eitherbefore molding or after a layer-up process.

In other embodiments, rather than providing a plurality of apertures 348that extend completely through the foot member 102 from a top surface115 to a bottom surface 118 visible in FIG. 6B, the prosthetic foot 300can comprise a plurality of recessed grooves or channels 348′ that donot extend completely through the foot member 102 (as illustrated inFIG. 6D). The recessed grooves 348′ can be formed either on a topsurface 115 of a prosthetic foot, a bottom surface 118 of a prostheticfoot, or in between a top surface and bottom surface. In one embodiment,the recessed grooves 348′ can assume the same shape (e.g., rectangular)and pattern across a width of the foot as the apertures 348 shown inFIG. 6A. The difference is that the recessed grooves 348′ only extendthrough a portion of the height of the foot from the top surface 115 toa bottom surface 118 of the foot. In some embodiments, the recessedgrooves 348′ have a depth D′ that is between about 1/10 to ¾ of theheight of the foot from a top surface to a bottom surface of the footmember 102. The depth of the recessed grooves 348′ can be between about0.05 mm and 6 mm, or between about 2 mm and 4 mm. In some embodiments,the foot member of the prosthetic foot 300 can include a combination ofboth apertures 348 that extend completely from a top surface 115 to abottom surface 118 of the foot and recessed grooves 348′ that extendonly partially from the top surface 115 or bottom surface 118 of thefoot.

In some embodiments, the plurality of recessed grooves can be formed byremoving layers of material from sections of the prosthetic foot. Forexample, in some embodiments in which the foot member of the prostheticfoot is formed of multiple layers of carbon (e.g., about 40 layers), itis possible to remove a number of the layers (e.g., between 5 and 30layers) to form recessed grooves in the foot member. Alternatively, thefoot member of the prosthetic foot can be formed by performing a speciallayup sequencing, in which the recessed grooves are defined by one ormore layers, but fewer than all layers, that make up the prosthetic foot300.

In some embodiments, the apertures 348 or recessed grooves 348′ can befilled with one or more filler materials. For example, as shown in theexploded view in FIG. 6C, the apertures 348 can be filled with a fillermaterial 154. The filler material 154 can comprise any of the materialsdescribed above, including various liquids, gels or solids, orcombinations thereof. In some embodiments, the filler material 154comprises a gummy material or polyurethane. One or more filler materials(e.g., two, three or more) can be used to occupy at least a portion (ifnot all) of one or more apertures 348 or recessed grooves 348′. Byproviding a filler material 154, this advantageously helps to furthercontrol the extent of articulation by the metatarsal hinge formed by theplurality of apertures 348 and/or recessed grooves 348′. In addition,using the filler material 154 can help provide better rolloverproperties for the foot. And in embodiments in which the prosthetic footis formed of layers of carbon fiber, which are subject to loosening orspringing, the filler material 154 helps to hold the layers together andin place.

The filler material 154 can be provided in a housing member as discussedabove that enhances the function of the filler material. In addition,the filler material 154 can be packaged or inserted in a membrane, suchthat in some embodiments, the filler material can be insertable and/orremovable from the apertures 348 or recessed grooves 348′. In someembodiments, only a portion of the apertures 348 or recessed grooves348′ are filled with a filler material, while in other embodiments, allof the apertures 348 or recessed grooves 348′ are filled with a fillermaterial.

In addition to the prosthetic feet 100, 200 and 300 described above, theinventive articulatable metatarsal joint formed of a channel or groove,as described herein, can be used with various other feet havingdifferent or additional features as described above. For example, themetatarsal hinge can be used with the prosthetic feet described in U.S.patent application Ser. No. 07/029,947, filed on Mar. 26, 1987, nowissued as U.S. Pat. No. 4,822,363 (Attorney Docket No. FLEXFT.024CP2),U.S. patent application Ser. No. 07/293,824, filed on Jan. 5, 1989, nowissued as U.S. Pat. No. 5,037,444 (Attorney Docket No. FLEXFT.003A),U.S. patent application Ser. No. 07/337,374, filed on Apr. 13, 1989, nowissued as U.S. Pat. No. 5,181,932 (Attorney Docket No. FLEXFT.010A),U.S. patent application Ser. No. 10/642,125, filed on Aug. 15, 2003(Attorney Docket No. OSSUR.042A), and U.S. patent application Ser. No.10/674,736, filed on Sep. 30, 2009 (Attorney Docket No. OSSUR.046A), allof which are incorporated by reference in their entireties.

Of course, the foregoing description is that of certain features,aspects and advantages of the present invention, to which variouschanges and modifications can be made without departing from the spiritand scope of the present invention. Moreover, the prosthetic foot neednot feature all of the objects, advantages, features and aspectsdiscussed above. Thus, for example, those skill in the art willrecognize that the invention can be embodied or carried out in a mannerthat achieves or optimizes one advantage or a group of advantages astaught herein without necessarily achieving other objects or advantagesas may be taught or suggested herein. In addition, while a number ofvariations of the invention have been shown and described in detail,other modifications and methods of use, which are within the scope ofthis invention, will be readily apparent to those of skill in the artbased upon this disclosure. It is contemplated that various combinationsor subcombinations of these specific features and aspects of embodimentsmay be made and still fall within the scope of the invention.Accordingly, it should be understood that various features and aspectsof the disclosed embodiments can be combined with or substituted for oneanother in order to form varying modes of the discussed prosthetic foot.Thus, it is intended that the present invention cover the modificationsand variations of this invention provided that they come within thescope of the appended claims or their equivalents.

1-21. (canceled)
 22. A prosthetic foot comprising: a plate-like footmember extending along a longitudinal axis between an anterior endgenerally corresponding to a toe portion of a foot and a posterior end,the foot member comprising a top surface, a bottom surface opposite thetop surface, and a groove extending downward from the top surface andextending between medial and lateral edges of the foot member, whereinthe groove intersects the longitudinal axis of the foot member at anangle other than 90 degrees, and wherein the groove is positioned alongthe length of the foot member at a location generally corresponding to ametatarsal region of a natural human foot, the groove configured toallow an anterior portion of the foot to controllably articulaterelative to a posterior portion of the foot.
 23. The prosthetic foot ofclaim 22, wherein the groove intersects the longitudinal axis of thefoot at an angle in the range of about 20 degrees to about 80 degrees.24. The prosthetic foot of claim 22, wherein the groove is shaped suchthat a cross-sectional width continuously decreases from a top to abottom of the elongate groove.
 25. The prosthetic foot of claim 22,wherein the groove is generally V-shaped.
 26. The prosthetic foot ofclaim 22, wherein the groove has a generally curved cross-sectionalshape.
 27. The prosthetic foot of claim 22, wherein a depth of thegroove is between about 1/20 and 9/10 of a cross-sectional thickness ofthe foot member.
 28. The prosthetic foot of claim 22, further comprisinga filling material disposed in the groove, the filling materialconfigured to vary the resistance to deflection of the foot membergenerally at the location of the groove.
 29. The prosthetic foot ofclaim 22, further comprising an adapter attached to the posterior end ofthe foot member.
 30. A prosthetic foot comprising: a plate-like footmember extending along a longitudinal axis between an anterior endgenerally corresponding to a toe portion of a foot and a posterior end,the foot member comprising a top surface and a bottom surface oppositethe top surface; and a groove defined by the foot member and extendingbetween medial and lateral edges of the foot member, wherein the groovecomprises at least a portion that extends at a non-perpendicular anglerelative to the longitudinal axis, and wherein the groove is positionedat a location generally corresponding to a metatarsal region of anatural human foot, the groove configured to allow an anterior portionof the foot to controllably articulate relative to a posterior portionof the foot.
 31. The prosthetic foot of claim 30, wherein the footmember is formed of a plurality of layers of a resilient material andthe groove is defined by one or more layers, but fewer than all of theplurality of layers of the foot member.
 32. The prosthetic foot of claim30, wherein the portion of the groove extends at an angle between about0 and about 85 degrees relative to a line extending transverse to thelongitudinal axis of the foot member.
 33. The prosthetic foot of claim30, wherein the portion of the groove extends at an angle between about0 and about 45 degrees relative to a line extending transverse to thelongitudinal axis of the foot member.
 34. The prosthetic foot of claim30, wherein the portion of the groove extends at an angle between about0 and about 20 degrees relative to a line extending transverse to thelongitudinal axis of the foot member.
 35. The prosthetic foot of claim30, wherein the groove is shaped such that a cross-sectional widthcontinuously decreases from a top to a bottom of the elongate groove.36. The prosthetic foot of claim 30, wherein the groove is generallyV-shaped.
 37. The prosthetic foot of claim 30, wherein the groove has agenerally curved cross-sectional shape.
 38. The prosthetic foot of claim30, wherein a depth of the groove is between about 1/20 and 9/10 of across-sectional thickness of the foot member.
 39. The prosthetic foot ofclaim 30, further comprising an adapter attached to the posterior end ofthe foot member.
 40. The prosthetic foot of claim 30, further comprisinga filling material disposed in the groove, the filling materialconfigured to vary the resistance to deflection of the foot membergenerally at the location of the groove.
 41. The prosthetic foot ofclaim 30, the groove further comprising a portion extending transverseto the longitudinal axis of the foot member.